Photovoltaic module mounting assembly

ABSTRACT

A mounting assembly (70c) for installing solar cell or photovoltaic modules (58) on a building surface (34) is disclosed. The mounting assembly (70c) includes a mounting device (74), a stud (114) that may be threaded to the mounting device (74), a clamping member (142) that may be positioned on the stud (114), and a nut (128) that may be threaded onto the stud (114) to secure the clamping member (142) to the mounting device (74). A mounting plate (110′) is disposed somewhere between the clamping member (142) and the mounting device (74). This mounting plate (110′) includes a raised structure or dome (174) on its upper surface (170) for positionally registering modules (58) thereto, a plurality of grounding projections (172) on this same upper surface (170), and a plurality of wiring tabs or clips (178) on its lower surface (176).

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Patent Application Ser. No. 61/310,178, that is entitled“PHOTOVOLTAIC SYSTEM FOR STANDING SEAM PANELS,” that was filed on Mar.3, 2010, and the entire disclosure of which is hereby incorporated byreference in its entirety herein.

FIELD OF THE INVENTION

The present invention generally relates to installing structures on abuilding surface and, more particularly, to a mounting assembly that maybe used to install one or more photovoltaic cell modules on such abuilding surface.

BACKGROUND

Metal panels are being increasingly used to define building surfacessuch as roofs and sidewalls. One type of metal panel is a standing seampanel, where the edges of adjacent standing seam panels of the buildingsurface are interconnected in a manner that defines a standing seam.Standing seam panels are expensive compared to other metal panels, andbuilding surfaces defined by metal panels may be more costly than othertypes of building surface constructions.

It is often desirable to install various types of structures on buildingsurfaces, such as heating, air conditioning, and ventilation equipment.Installing structures on standing seam panel building surfaces in amanner that punctures the building surface at one or more locations isundesirable in a number of respects. One is simply the desire to avoidpuncturing what is a relatively expensive building surface. Another isthat puncturing a metal panel building surface can present leakage andcorrosion issues.

Photovoltaic or solar cells have existed for some time, and have beeninstalled on various building roofs. A photovoltaic cell is typicallyincorporated into a perimeter frame of an appropriate material (e.g.,aluminum) to define a photovoltaic module or solar cell module. Multiplephotovoltaic modules may be installed in one or more rows (e.g., astring) on a roofing surface to define an array.

FIG. 1 illustrates one prior art approach that has been utilized tomount a solar cell module to a standing seam. A mounting assembly 10includes a mounting device 74, a bolt 14, and a clamping member 142.Generally, the mounting device 74 includes a slot 90 that receives atleast an upper portion of a standing seam 42. A seam fastener 106 isdirected through the mounting device 74 and into the slot 90 to forciblyretain the standing seam 42 therein. This then mounts the mountingdevice 74 to the standing seam 42.

A threaded shaft 22 of the bolt 14 from the mounting assembly 10 passesthrough an unthreaded hole in a base 154 of a clamping member 142, andinto a threaded hole 98 on an upper surface 78 of the mounting device74. This then mounts the clamping member 142 to the mounting device 74.The clamping member 142 is used to interconnect a pair of differentsolar cell module frames 62 with the mounting assembly 10. In thisregard, the clamping member 142 includes a pair of clamping legs 146,where each clamping leg 146 includes an engagement section 152 that isspaced from the upper surface 78 of the mounting device 74. The bolt 14may be threaded into the mounting device 74 to engage a head 18 of thebolt with the base 154 of the clamping member 142. Increasing the degreeof threaded engagement between the bolt 14 and the mounting device 74causes the engagement sections 152 of the clamping legs 146 to engagethe corresponding solar cell module frame 62 and force the same againstthe upper surface 78 of the mounting device 74.

SUMMARY

The present invention is embodied by a mounting assembly that may beused to mount photovoltaic modules or solar cell modules on a buildingsurface (e.g., one defined by a plurality of interconnected panels andthat includes a plurality of standing seams (e.g., a standing seam maycoincide with where a pair of panels are nested together and/orinterlocked)) or any other appropriate structure. This mounting assemblyincludes a mounting device, a mounting plate, a clamping member or apull-down grab member, and a threaded clamp fastener. The mountingdevice may be mounted in any appropriate manner to a building surface(e.g., configured for attachment to a standing seam). The mounting plateis positioned on the mounting device (e.g., on an upper surface) and istypically larger than the mounting device so as to be able to supportone or more photovoltaic modules when the mounting assembly is installedon the building surface. The threaded clamp fastener extends through theclamping member, through the mounting plate, and is secured to themounting device in any appropriate manner (e.g., via threaded engagementwith the mounting device). The mounting plate may be located somewherebetween the mounting device and the clamping member in the installedconfiguration.

Various refinements exist of the above-noted features of the presentinvention. Further features may also be incorporated by the presentinvention as well. These refinements and additional features may beutilized individually or in any combination.

The mounting assembly may be installed on any appropriate surface, suchas a building surface. This building surface may be in the form of aroof, and also may be in the form of siding. In one embodiment, themounting device is installed on a standing seam defined by an adjacentpair of interconnected panels that are typically fabricated from a metalor a metal alloy. Each of the components of the mounting assembly may beof any appropriate size, shape, configuration, and/or type, may beformed from any appropriate material or combination of materials, orboth. For instance, each of the components of the mounting assembly maybe formed from an appropriate metal or metal alloy.

The mounting device may be installed on a standing seam of a buildingsurface without penetrating or piercing the standing seam. In thisregard, the mounting device may include a slot in which at least anupper portion of a standing seam may be disposed. At least one fastenermay extend through the mounting device (e.g., via a threaded engagementor interaction) and may engage a standing seam that is at leastpartially disposed within the slot. In one embodiment, each suchseam-engaging fastener includes a convex, rounded, or blunt-nose end forinterfacing with a standing seam in a manner that forces the standingseam toward or against the opposing sidewall of the slot for themounting device. Notwithstanding the foregoing, the mounting device maybe of any appropriate configuration (e.g., in the form of a rail, track,or the like, such as a uni-strut), and may be mounted on any appropriatebuilding surface in any appropriate manner.

The mounting assembly may be part of what may be characterized asphotovoltaic system in the form of a building surface (e.g., having aplurality of standing seams and a plurality of interconnected panels), aplurality of the above-noted mounting assemblies mounted to the buildingsurface, and first and second photovoltaic modules. A first mountingassembly of this plurality of mounting assemblies may simultaneouslyengage each of the first and second photovoltaic modules. In thisregard, the clamping member may include first and second clamping legsor sections. With the first and second photovoltaic modules beingpositioned on the upper surface of the mounting plate of the firstmounting assembly, the first clamping leg of the first mounting assemblymay be engaged with the first photovoltaic module, and the secondclamping leg of the first mounting assembly may be engaged with thesecond photovoltaic module. Any appropriate threaded clamp fastener maybe utilized to activate a clamping action of the clamping member inrelation to the first and second photovoltaic modules (e.g., a threadedstud having at least one nut threaded thereon; a bolt).

Various features may be incorporated by the mounting plate to facilitateone or more aspects of the installation of a photovoltaic system. Forinstance, the mounting plate may incorporate one or more features tofacilitate the alignment/positioning of one or more photovoltaic modulesrelative to the mounting assembly for/during installation. The mountingplate may incorporate one or more features to facilitate the groundingof a photovoltaic module that is engaged/secured by the correspondingmounting assembly. The mounting plate may incorporate one or more wiremanagement features. Each of these three overall/general features may beindividually incorporated by the mounting plate. Any and allcombinations of these three overall/general features may be incorporatedby the mounting plate as well.

The mounting plate may be of any appropriate size, shape, and/orconfiguration (e.g., a circular outer perimeter; a square outerperimeter; a rectangular outer perimeter), may be formed from anyappropriate material or combination of materials (e.g., a metal or metalalloy), or both. The mounting plate may include an upper surface and anoppositely disposed lower surface, with the lower surface being incontact with the mounting device (e.g., its upper surface) when themounting assembly is installed on a building surface.

The upper surface of the mounting plate may include first and second PVmodule positional registrants. These first and second PV modulepositional registrants may be utilized to dispose first and second PVmodules on the upper surface of the mounting plate in a position forproper engagement by the clamping member. In one embodiment, the firstPV module is positioned in at least adjacent relation to the first PVmodule positional registrant and the second PV module is positioned inat least adjacent relation to the second PV module positionalregistrant. In one embodiment, the first PV module actually butts upagainst the first PV module positional registrant (e.g., the first PVmodule positional registrant disposes the first PV module in a certainposition on the mounting plate), while the second PV module actuallybutts up against the second PV module positional registrant (e.g., thesecond PV module positional registrant disposes the second PV module ina certain position on the mounting plate).

Each of the above-noted first and second PV module positionalregistrants may be of any appropriate size, shape, configuration, and/ortype, and furthermore may be disposed in any appropriate arrangement onthe upper surface of the mounting plate. In one embodiment the uppersurface of the mounting plate includes what may be characterized as araised structure (e.g., of a continuous or unitary nature). First andsecond portions on a perimeter of this raised structure may becharacterized as the noted first and second PV module positionalregistrants.

The threaded clamp fastener may extend through a center of the raisedstructure on the upper surface of the mounting plate. An outer perimeterof the raised structure may be circular in a plan view. The raisedstructure may be centrally disposed relative to an outer perimeter ofthe mounting plate. An outer perimeter of the raised structure and anouter perimeter of the mounting plate may be concentric orconcentrically disposed relative to the threaded clamp fastener. Theraised structure may be characterized as annular, doughnut-shaped, ringor ring-like, or any combination thereof. In any case, the raisedstructure may be integrally formed with a remainder of the mountingplate, such that the need to separately attach the raised structure tothe mounting plate may be alleviated (e.g., the mounting plate and theraised structure may be a one-piece structure).

The raised structure may be a configuration that alleviates the need toposition the mounting plate on the mounting device in any particularorientation. Consider the case where a first reference line extends fromthe threaded clamp fastener and remains in a fixed position relative tothe mounting plate, where a second reference line extends from thethreaded clamp fastener and moves along with the mounting plate as themounting plate is rotated relative to the mounting device about thethreaded clamp fastener, and where the first and second reference linesare contained within a common plane. The raised structure may be of aconfiguration that allows for any angle between the first and secondreference lines (including the case where there is no angle at all or a“zero angle”), and yet still allows the raised structure to be used topositionally register each of first and second photovoltaic modulesrelative to the mounting plate (e.g., by the first and second PV modulesengaging oppositely disposed portions on the perimeter of the raisedstructure).

The first and second PV module positional registrants may be separateand discrete structures (i.e., not different portions of a commonstructure, such as the above-noted raised structure). The first andsecond PV module positional registrants in this case may be disposedalong a common reference line that passes through the threaded clampfastener. Although the first and second PV module positional registrantsmay be disposed at different distances from the threaded clamp fastener,in one embodiment the first and second PV module positional registrantsare disposed the same distance from the threaded clamp fastener.

An installer could visually determine the proper orientation for themounting plate on the mounting device when the first and second PVmodule positional registrants are separate and discrete structures.However, it may be desirable to include at least one mounting devicepositional registrant on a lower surface of the mounting plate forpurposes of establishing a desired positioning of the mounting plate onthe mounting device (e.g., such that the clamping member shouldsufficiently engage each of a pair of adjacently disposed photovoltaicmodules). Each such mounting device positional registrant may be of anyappropriate size, shape, configuration, and/or type (e.g., tabs, pins,posts, or the like). In one embodiment, a pair of mounting devicepositional registrants is utilized to engage oppositely disposedportions of the mounting device (e.g., a pair of oppositely disposedends of the mounting device, for instance where a slot on a lowersurface of the mounting device extends between these two oppositelydisposed ends; a pair of oppositely disposed side surfaces) to disposethe mounting plate in a desired position relative to the mountingdevice.

The upper surface of the mounting plate may include what may becharacterized as a plurality of “grounding projections.” Each suchgrounding projection may be of any appropriate size, shape,configuration, and/or type. The grounding projections may be integrallyformed with a remainder of the mounting plate, such that the need toseparately attach each grounding projection to the mounting plate isalleviated (e.g., the mounting plate and the plurality of groundingprojections may be a one-piece structure).

The various grounding projections may be of a configuration thatfacilitates establishing an electrical connection with and/or providinga grounding function for a photovoltaic module (e.g., by engaging aframe of such a photovoltaic module, and which may require that thegrounding projection(s) pierce or penetrate a surface or surface coatingof this frame). For instance, each grounding projection couldincorporate one or more edges to desirably interface with acorresponding photovoltaic module. One or more of the groundingprojections could be in the form of a tooth or a tooth-like structure.One or more of the grounding projections could be in the form of ahollow cylinder that incorporates at least one edge on a free endthereof.

The plurality of grounding projections may be characterized as beingspaced about the threaded clamp fastener. The plurality of groundingprojections may be equally spaced about the threaded clamp fastener(e.g., located every 90° in the case where there are four groundingprojections). In one embodiment, each grounding projection on the uppersurface of the mounting plate is located further from the threaded clampfastener than each of the first and second PV module positionalregistrants.

Any appropriate number of grounding projections may be utilized on theupper surface of the mounting plate, and multiple grounding projectionsmay be disposed in any appropriate arrangement. One embodiment has atleast one grounding projection engaged with each photovoltaic module(e.g., its frame) that is placed on the mounting plate. It should beappreciated that a first grounding projection or a first set ofgrounding projections could engage a first photovoltaic module placed onthe mounting plate, and that a second grounding projection or a secondset of grounding projections could engage a second photovoltaic moduleplaced on the mounting plate, where the first and second groundingprojections are different ones of the plurality of groundingprojections, and where the first and second sets of groundingprojections do not include any common grounding projections.

The number and/or arrangement of the plurality of grounding projectionsmay be selected so as to alleviate the need to position the mountingplate on the mounting device in any particular orientation, and yetstill allow one or more of the grounding projections to be in contactwith each photovoltaic module positioned on the mounting plate. Considerthe case where a first reference line extends from the threaded clampfastener and remains in a fixed position relative to the mounting plate,where a second reference line extends from the threaded clamp fastenerand moves along with the mounting plate as the mounting plate is rotatedrelative to the mounting device about the threaded clamp fastener, andwhere the first and second reference lines are contained within a commonplane. The number and/or arrangement of the plurality of groundingprojections may be selected such that any angle may exist between thefirst and second reference lines (including the case where there is noangle at all or a “zero angle”), and yet still allow one or moregrounding projections to be in contact with each photovoltaic modulepositioned on the mounting plate.

The lower surface of the mounting plate may include at least one wiringclip, including where this lower surface includes a plurality of wiringclips. Any appropriate number of wiring clips may be utilized. Multiplewiring clips may be spaced about the threaded clamp fastener, andincluding in equally-spaced relation (e.g., every 90° in the case wherethere are four of such wiring clips). In one embodiment, each wiringclip on the lower surface of the mounting plate is located further fromthe threaded clamp fastener than each of the first and second PV modulepositional registrants.

The wiring clips may be of any appropriate configuration that allows oneor more wires to be retained in the space between the wiring clip andthe lower surface of the mounting plate. A portion of each wiring clipmay be disposed in at least generally parallel and spaced relation tothe lower surface of the mounting plate, and this portion may include arecessed region to facilitate the retention of one or more wires,quick-connect leads, or the like therein.

Multiple wiring clips may be disposed in any appropriate arrangement onthe lower surface of the mounting plate. Although each mounting clipcould be separately attached to the mounting plate, in one embodimenteach mounting clip is integrally formed with the remainder of themounting plate (e.g., such that the mounting plate and each of itsmounting clips is a one-piece structure). Consider the case where themounting clips are “stamped” from the body of the mounting plate. Theresulting aperture in the mounting plate may also be utilized in theinstallation of photovoltaic modules. For instance, an installer maydirect a cable or zip tie through such an aperture to bundle a pluralityof wires or the like together that are located underneath the mountingassembly or in the space between an adjacent pair of PV modules.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a side view of a prior art mounting assembly forinterconnecting solar cell modules with a standing seam roof.

FIG. 2 is a perspective view of a plurality of solar cell modulesinstalled on a standing seam building surface using a plurality ofadjustable mounting assemblies.

FIG. 3 is a cross-sectional schematic of a representative standing seamdefined by interconnecting a pair of panels.

FIG. 4 is a top view of one of the solar cell modules illustrated inFIG. 2.

FIG. 5 is a perspective view of one of the mounting devices that isinstalled on a standing steam in FIG. 2.

FIG. 6 is an exploded, perspective view of one of the adjustablemounting assemblies from FIG. 2.

FIG. 7A is a side view of one of the adjustable mounting assemblies fromFIG. 2, and which is engaging a pair of solar cell module frames.

FIG. 7B shows the mounting assembly of FIG. 7A being used for solar cellmodule frames having a different thickness than those illustrated inFIG. 7A.

FIG. 7C is a side view of one of the adjustable mounting assemblies fromFIG. 2 that is disposed adjacent to an edge of the building surface, andwhich is engaging a single solar cell module frame.

FIG. 8A is one side-based perspective view of another embodiment of amounting assembly for photovoltaic modules.

FIG. 8B is one top-based perspective view of the mounting assembly ofFIG. 8A.

FIG. 8C is another one top-based perspective view of the mountingassembly of FIG. 8A.

FIG. 8D is a bottom-based perspective view of the mounting assembly ofFIG. 8A.

FIG. 8E is a plan view of a bottom of the mounting assembly of FIG. 8A.

FIG. 8F is another side-based perspective view of the mounting assemblyof FIG. 8A, and schematically illustrating the engagement of a pair ofphotovoltaic modules.

FIG. 9A is a plan view of one embodiment of a photovoltaic system usinga plurality of the mounting assemblies of FIGS. 8A-F, and with theclamping members being removed to illustrate a positional registrationfunction incorporated by the mounting plate of such mounting assemblies.

FIG. 9B is a plan view of a photovoltaic system using a plurality of themounting assemblies of FIG. 6, and with the clamping members beingremoved therefrom to illustrate how a misaligned mounting assembly canaffect the ability of the same to clamp onto one or more photovoltaicmodules.

FIG. 10A is a perspective view of another embodiment of a mounting platethat incorporates a discrete pair of PV module positional registrants.

FIG. 10B is a side view of the mounting plate of FIG. 10 disposed on amounting device, where the mounting plate includes a pair of mountingdevice positional registrants.

DETAILED DESCRIPTION

FIG. 2 illustrates an assembly 30 in the form of a building surface 34,a photovoltaic or solar cell array 54 defined by a plurality ofphotovoltaic modules or solar cell modules 58 (only schematically shownin FIG. 2), and a plurality of mounting assemblies 70 a, 70 b. Thebuilding surface 34 is defined by interconnecting a plurality of panels38. Although the panels 38 may be formed from any appropriate materialor combination of materials, typically they are in the form of metalpanels 38. In any case, each adjacent pair of panels 38 isinterconnected in a manner so as to define a standing seam 42 (onlyschematically shown in FIG. 2). A base 46 is disposed between theopposing edges of each panel 38 (e.g., FIG. 3). The entirety of the base46 may be flat or planar. However, one or more small structures may beformed/shaped into the base 46 of one or more panels 38 of the buildingsurface 34 to address oil canning. These structures are commonlyreferred to as crests, minor ribs, intermediate ribs, pencil ribs,striations, fluting, or flutes.

A cross-sectional schematic of one of the standing seams 42 isillustrated in FIG. 3. There it can be seen that a pair ofinterconnected panels 38 define a standing seam 42. Generally, an edgeor edge section 50 of one panel 38 is “nested” with the opposing edge oredge section 50 of the adjacent panel 38 to define a standing seam 42.Typically each the two opposing edges 50 of a given panel 38 will be ofa different configuration. That way, one edge 50 (one configuration) ofone panel 38 will be able to “nest” with one edge 50 (anotherconfiguration) of the adjacent panel 38. Various configurations may beemployed for the edges 50 of the panels 38, and which may providedifferent configurations/profiles for the corresponding standing seam42.

A more detailed view of one of the photovoltaic modules or solar cellmodules 58 from FIG. 2 is presented in FIG. 4. Each solar cell module 58includes a frame 62 that is disposed about the corresponding solar cell66. The frame 62 may be of any appropriate size, shape, configuration,and/or type, and may be formed from any appropriate material orcombination of materials. In the illustrated embodiment, the frame 62 isof a rectangular profile, and may be formed from an appropriate metal ormetal alloy (e.g., aluminum). Similarly, the photovoltaic cell or solarcell 66 may be of any appropriate size, shape, configuration and/or typeto convert light into electricity. Typically the solar cell 66 will bein the form of a substrate having a stack of a plurality of layers. Anynumber of solar cell modules 58 may be used for the solar cell array 54of FIG. 2, and multiple solar cell modules 58 may be disposed in anyappropriate arrangement.

The mounting assemblies 70 a, 70 b that are used to install the solarcell array 54 onto the building surface 34 in FIG. 2 utilize a mountingdevice 74 that may be of any appropriate size, shape, configuration,and/or type. One configuration of a mounting device that may beinstalled on a standing seam 42 is illustrated in FIG. 5 and isidentified by reference numeral 74. This mounting device 74 includes anupper surface 78 and an oppositely disposed bottom surface 86, a pair ofoppositely disposed side surfaces 82, and a pair of oppositely disposedends 94. The upper surface 78 includes a threaded hole 98, as does atleast one of the side surfaces 82, while the bottom surface 86 includesa slot 90 that extends between the two ends 94 of the mounting device74.

The slot 90 on the bottom surface 86 of the mounting device 74 includesa base 92 a and a pair of sidewalls 92 b that are spaced apart toreceive at least an end section of a standing seam 42. One or more seamfasteners 106 may be directed through a threaded hole 102 of themounting device 74 and into the slot 90 to engage the standing seam 42and secure the same against the opposing slot sidewall 92 b. A cavity ofany appropriate type may be on this opposing slot sidewall 92 b to allowthe aligned seam fastener 106 to deflect a corresponding portion of thestanding seam 42 into this cavity, although such may not be required inall instances. In any case and in one embodiment, the seam fastener 106only interfaces with an exterior surface of the standing seam 42. Forinstance, the end of the seam fastener 106 that interfaces with thestanding seam 42 may be convex, rounded, or of a blunt-nosedconfiguration to provide a desirable interface with the standing seam42.

Other mounting device configurations may be appropriate for mounting onstanding seam 42 and that may be used in place of the mounting device 74shown in FIG. 5. Various mounting device configurations are disclosed inU.S. Pat. Nos. 5,228,248; 5,483,772; 5,941,931; 5,694,721; 5,715,640;5,983,588; 6,164,033; 6,718,718; 7,100,338; and 7,013,612, and which maybe utilized by either of the mounting assemblies 70 a, 70 b.

The mounting assembly 70 a that is used in the installation of a pair ofadjacent solar cell modules 58 in FIG. 2, and that may use a mountingdevice 74, is illustrated in FIG. 6. The mounting assembly 70 a includesa mounting device 74, along with a mounting plate 110, a clamping member142, a stud 114, and a nut 128. The mounting plate 110 is disposed onthe upper surface 78 of the mounting device 74, and includes a hole oraperture 112 that allows the stud 114 to pass therethrough. The mountingplate 110 may be utilized when it may be desirable to enhance thestability of the mounting assembly 70 a, and in any case may be of anyappropriate size, shape, configuration and/or type. The surface area ofthe mounting plate 110 is at least about 5 in² in one embodiment, and isat least about 7 in² in another embodiment. It may be possible toeliminate the mounting plate 110 from the mounting assembly 70 a, forinstance when the surface area of the upper surface 78 of the mountingdevice 74 is sufficiently large.

The stud 114 provides an interface between the clamping member 142 andthe mounting device 74, and includes a first stud end 118 and anoppositely disposed second stud end 122. A nut 126 is disposed betweenthe first stud end 118 and the second stud end 122, and is fixed to thestud 114 in any appropriate manner (e.g., welded). That is, the nut 126does not move relative to the stud 114, such that the nut 126 and stud114 will move together as a single unit. In one embodiment, the nut 126is threaded onto the stud 114, and is then fixed in the desiredlocation.

A first threaded section 130 a extends from the first stud end 118toward the second stud end 122, while a second threaded section 130 bextends from the second stud end 122 toward the first stud end 118. Anunthreaded section 134 is disposed between the fixed nut 126 and thefirst threaded section 130 a in the illustrated embodiment. However, thefirst threaded section 130 a could extend all the way to the fixed nut126 (e.g., the entire stud 114 could be threaded). In one embodiment,the length of the first threaded section is at least about 1.5 inches.

The second stud end 122 may be directed through the hole 112 in themounting plate 110 if being utilized, and in any case into a threadedhole 98 of the mounting device 74. It should be appreciated that themounting device 74 could also be disposed in a horizontal orientation ona standing seam having a horizontally disposed end section versus thevertically disposed orientation of the end section of the standing seam42, and that in this case the second stud end 122 would be directed intothe threaded hole 98 on a side surface 82 of the mounting device 74(e.g., the mounting plate 110 could then be disposed on such a sidesurface 82 if desired/required). In any case, the stud 114 may betightened onto the mounting device 74 by having an appropriate toolengage the fixed nut 126 to rotate the stud 114 relative to the mountingdevice 74 and into a desired forcible engagement with the mounting plate110 or with the corresponding surface of the mounting device 74 if themounting plate 110 is not being used. In one embodiment, the fixed nut126 is located along the length of the stud 114 such that the secondstud end 122 does not extend into the slot 90 of the mounting device 74when the stud 114 is tightened onto the mounting device 74. Having thisstud end 122 extend into the slot 90 could potentially damage thestanding seam 42.

The clamping member 142 includes a base 154 that is disposed on thefixed nut 26 of the stud 114. A hole 158 extends through the base 154and is aligned with a threaded hole 98 of the mounting device 74. In theillustrated embodiment, the hole 156 in the clamping member 142 is notthreaded such that the clamping member 142 may “slide” along the stud114.

A pair of clamping legs 146 that are disposed in opposing relationextend upwardly from the base 154 in a direction that is at leastgenerally away from the mounting device 74 when the mounting assembly 70a is installed, such that the base 154 and clamping legs 146 define anat least generally U-shaped structure. Each clamping leg 146 includes anextension 150 and an engagement section 152. The engagement sections 152are disposed in a different orientation than the extensions 150, andfunction to provide a surface to engage and clamp a structure to themounting assembly 70 a. In the illustrated embodiment, the engagementsections 150 include teeth, serrations, or like to enhance the “grip” onthe structure being clamped to the mounting assembly 70 a. The clampinglegs 146 may be of any appropriate size, shape, and/or configuration forclamping a structure to the mounting assembly 70 a. Generally, a pocket160 is defined between each engagement section 152 and the underlyingmounting plate 110/mounting device 74 for receiving a structure to beclamped to the mounting assembly 70 a.

FIG. 7A illustrates one of the mounting assemblies 70 a from FIG. 2, andwhich again interfaces with a pair of solar cell modules 58.Installation of such a mounting assembly 70 a could entail directing atleast the upper portion of the standing seam 42 into the slot 90 of themounting device 74. Thereafter, the mounting device 74 may be secured tothe standing seam 42 using at least one seam fastener 106. Once again,the seam fastener 106 may be directed through the mounting device 74 andinto the slot 90 to force a corresponding portion of the standing seam42 against the opposing slot sidewall 92 b.

The mounting plate 110 may be disposed on the upper surface 78 of themounting device 74 such that its hole 112 is aligned with a threadedhole 98 on the mounting device 74 that will receive the stud 114. Thesecond stud end 122 may then be directed through the hole 112 of themounting plate 110 such that the stud 114 may be threaded to themounting device 74 (e.g., using a wrench on the fixed nut 126 to clampthe mounting plate 110 between the fixed nut 126 and the mounting device74). At this time, the lower surface of the fixed nut 126 engages theupper surface of the mounting plate 110 or a corresponding surface ofthe mounting device 74 if the mounting plate 110 is not used. Aspreviously noted, and as illustrated in FIG. 7A, in one embodiment thesecond stud end 122 does not pass into the slot 90 of the mountingdevice 74. It should be appreciated that the mounting plate 110 and stud114 could be installed on the mounting device 74 prior to itsinstallation on the standing seam 42.

A frame 62 from one of the solar cell modules 58 may be positioned onone side of the mounting plate 110, while a frame 62 from another of thesolar cell modules 58 may be positioned on the opposite side of themounting plate 110. The clamping member 142 may or may not be positionedon the stud 114 at the time the solar cell module frames 62 arepositioned on the mounting plate 110. In any case, the first stud end118 may be directed through the hole 158 on the base 154 of the clampingmember 142. At this time a portion of one solar cell module frame 62will then be positioned between the mounting plate 110 and theengagement section 152 of one of the clamping legs 146, while a portionof another solar cell module frame 62 will then be positioned betweenthe mounting plate 110 and the engagement section 152 of the otherclamping leg 146. The nut 128 may then be threaded onto the first studend 118 of the stud 114 until the engagement sections 152 of theclamping member 142 exert a desired force on the two solar cell moduleframes 62 (e.g., to clamp these frames 62 between the engagementsections 152 of the clamping member 142 and the mounting plate 110, orbetween the engagement sections 152 of the clamping member 142 and themounting device 74 if the mounting plate 110 is not being used). Thatis, turning the nut 128 may move the clamping member 142 along the stud114 and toward the mounting device 74 (e.g., by the clamping member 142“sliding” along the stud 114) to generate the desired clamping action.It should be appreciated that the clamping member 142 and possibly thenut 128 could be positioned on the stud 114 at the time when the solarcell module frames 62 are disposed on the mounting plate 110, althoughthis may require that the clamping member 142 be lifted to a degree atthis time to accommodate positioning the frames 62 under the engagementsections 152 of the clamping member 142.

As evident by a review of FIG. 7A, the stud 114 may extend beyond thenut 128 in the installed configuration. Preferably the first threadedsection 130 a of the stud 114 is of a length that allows the mountingassembly 70 a to be used to clamp structures of various thicknesses tothe mounting assembly 70 a. For instance, FIG. 7B illustrates a pair ofsolar cell module frames 62′ being clamped to the mounting assembly 70a, where these frames 62′ are thicker than the frames 62 presented inFIG. 7A. In one embodiment, the length of the first threaded section 130a is at least about 1.5 inches, and which accommodates using themounting assembly 70 a to clamp solar cell modules of a number ofdifferent thicknesses (e.g., the fixed nut 126 may be spaced from thefirst stud end 118 by a distance of at least about 1.5 inches, the firstthreaded section 130 a may extend all the way to the fixed nut 126, orboth).

The above-described mounting assemblies 70 a may be used tosimultaneously engage the frame 62 of a pair of solar cell modules 58.In at least some cases, there may only be a need to engage a singlesolar cell 58, such as in the case of those solar cells 58 that aredisposed closest to an edge 36 of the building surface 34 (FIG. 2). FIG.7C illustrates a configuration for this situation, and which isidentified by reference numeral 70 b. Corresponding parts of themounting assemblies 70 a and 70 b are identified by the same referencenumeral. The only difference between the mounting assembly 70 b and themounting assembly 70 a is that an additional nut 128 is used by themounting assembly 70 b. Therefore, the remainder of the discussionpresented above also applies to the mounting assembly 70 b.

Generally, one nut 128 is threaded onto the first stud end 118, followedby positioning a clamping member 142 over the first stud end 118 andonto the stud 114, then followed by a second nut 128 that is threadedonto the first stud end 118. The lower nut 128 may be threaded down asufficient distance on the stud 114. Thereafter, the top nut 128 may bethreaded to clamp a solar cell module frame 62″ between the mountingplate 110 and the engagement section 152 of one of the clamping members142. The lower nut 128 may then be threaded upwardly on the stud 118 toengage the underside of the base 154 of the clamping member 142.

Another embodiment of a mounting assembly, which may be used formounting photovoltaic or solar cell modules to a building surface havinga plurality of standing seams defined by a plurality of interconnectedpanels, is illustrated in FIGS. 8A-F and is identified by referencenumeral 70 c. Corresponding components between the mounting assembly 70c and the above-discussed mounting assembly 70 a are identified by thesame reference numerals. Those corresponding components between thesetwo embodiments that differ in at least some respect are identified bythe same reference numeral, but with a “single prime” designation inrelation to the mounting assembly 70 c.

The mounting assembly 70 c of FIGS. 8A-F utilizes the above-discussedmounting device 74, clamping member 142, and stud 114. All of thefeatures discussed above in relation to each of these components remainequally applicable to the mounting assembly 70 c. The mounting assembly70 c does utilize a mounting plate 110′ that is positioned on an uppersurface 78 of the mounting device 74, and that is located between theclamping member 142 and the mounting device 74 in a dimensioncorresponding with the length dimension of the stud 114. However, themounting place 110′ is of a different configuration than the mountingplate 110 utilized by the mounting assembly 70 a, and therefore thenoted “single prime” designation is utilized.

The mounting plate 110′ includes an upper surface 170 and an oppositelydisposed lower surface 176. The upper surface 170 includes a pluralityof grounding projections 172. The grounding projections 172 may beintegrally formed with a remainder of the mounting plate 110′ (e.g., themounting plate 110′ and grounding projections 172 may be of one-piececonstruction, such that the individual grounding projections 172 do notneed to be separately attached to the mounting plate 110′). Anyappropriate number of grounding projections 172 may be utilized. Eachgrounding projection 172 may be of any appropriate size, shape, and/orconfiguration. The various grounding projections 172 may be equallyspaced from the stud 114, may be equally spaced about the stud 114, orboth.

In one embodiment, the number of grounding projections 172 is selectedand the grounding projections 172 are arranged such that at least onegrounding projection 172 will engage each photovoltaic module beingmounted to a building surface by the clamp assembly 70 c, regardless ofthe angular position of the mounting plate 110′ relative to the stud114. “Angular position” does not mean that the mounting plate 110′ isdisposed at an angle relative to the upper surface 78 of the mountingdevice 74. Instead, “angular position” means a position of the mountingplate 110′ that may be realized by rotating the mounting plate 110′relative to the stud 114 and/or the mounting device 74. Consider thecase where the ends 94 of the mounting device 74 define the 12 o'clockand 6 o'clock positions. The mounting plate 110′ may be positioned onthe mounting device 74 with each of its grounding projections 172 beingdisposed at any angle relative to the 12 o'clock position (e.g., in the1 o'clock position, in the 2 o'clock position, in the 8 o'clockposition, etc), and yet at least one grounding projection 172 willengage each photovoltaic module being mounted to a building surface bythe clamp assembly 70 c. The “angle” of each such grounding projection172 is the angle between first and second reference lines that aredisposed within a common plane, the first reference line remaining in afixed position relative to the mounting plate 110′ and extending fromthe stud 114, for instance, to the noted 12 o'clock position. The secondreference line may also extend from the stud 114 to a particulargrounding projection 172, and thereby may rotate along with the mountingplate 110′ as its angular position is adjusted relative to the stud 114and/or mounting device 74.

The mounting device 110′ also includes a raised structure 174 on itsupper surface 170. The raised structure 174 may be disposed about theun-threaded hole 112 in the mounting plate 110′ and through which thestud 114 passes. Generally and as will be discussed in more detailbelow, the raised structure 174 may be used to determine where aphotovoltaic module should be positioned on the upper surface 170 of themounting plate 110′ to ensure that the clamping member 142 willadequately engage not only this photovoltaic module, but an adjacentlydisposed photovoltaic module as well. As such, the raised structure 174may be characterized as a positional registrant or alignment feature foreach adjacent pair of photovoltaic modules being clamped by a commonmounting assembly 70 c.

The raised structure 174 may be integrally formed with a remainder ofthe mounting plate 110′ (e.g., the mounting plate 110′ and raisedstructure 174 may be of one-piece construction, such that the raisedstructure 174 does not need to be separately attached to the mountingplate 110′). The raised structure 174 may be characterized as beingdoughnut-shaped. The raised structure 174 may extend completely aboutthe stud 114, the stud 114 may extend through a center of the raisedstructure 174, or both. The raised structure 174 may be circular in aplan view. This alleviates the requirement to have the mounting plate110′ be in a certain angular position on the upper surface 78 of themounting device 74 to provide its positional registration or alignmentfunction in relation to the photovoltaic modules to be clamped. An outerperimeter of the raised structure 174 and an outer perimeter of themounting plate 110′ may be concentrically disposed relative to the stud114. The raised structure 174 may be centrally disposed relative to anouter perimeter of the mounting plate 110′.

The lower surface 176 of the mounting plate 110′ includes a plurality ofwiring tabs or clips 178. The wiring clips 178 may be integrally formedwith a remainder of the mounting plate 110′ (e.g., the mounting plate110′ and wiring clips 178 may be of one-piece construction, such thatthe individual wiring clips 178 do not need to be separately attached tothe mounting plate 110′). For instance, the wiring clips 178 could be“stamped” from the body of the mounting plate 110′. In this regard, themounting plate 110′ includes an aperture 184 for each such wiring clip178. Any appropriate number of wiring clips 178 may be utilized. Thevarious wiring clips 178 may be equally spaced from the stud 114, may beequally spaced about the stud 114, or both.

In one embodiment, the number of wiring clips 178 is selected and thewiring clips 178 are arranged such that at least one wiring clip 178should be available for holding/retaining one or more wires from/foreach photovoltaic module being mounted to a building surface by theclamp assembly 70 c, regardless of the angular position of the mountingplate 110′ relative to the stud 114 and/or mounting device 74.

Each wiring clip 178 may be of any appropriate size, shape, and/orconfiguration. In the illustrated embodiment, each wiring clip 178includes a first segment 180 a that extends away from the lower surface176 of the mounting plate 110′, along with a second segment 180 b thatextends from a distal end of the first segment 180 a. The second segment180 b may be disposed at least generally parallel with the lower surface176 of the mounting plate 110′. In any case, the second segment 180 bmay include a recessed region 182 (e.g., a concave area) to facilitateretention of one or more wires and/or quick-connect leads.

A wiring clip 178 may be used the support and/or retain thequick-connect lead(s) associated with one of the photovoltaic modulesbeing clamped by the corresponding mounting assembly 70 c (e.g., bybeing positioned within the space between the second segment 180 b of agiven wiring clip 178 and the lower surface 176 of the mounting plate110′, for instance by resting in a concave portion of the second segment180 b in the form of the noted recessed region 182). Other wires couldbe directed into the space between the second segment 180 b of a givenwiring clip 178 and the lower surface 176 of the mounting plate 110′.

Another function is indirectly provided by the wiring clips 178. Theaperture 184 associated with each wiring clip 178 provides a spacethrough which an installer may direct cable or zip tie or the like tobundle together various wires that may be located at a lower elevationthan the mounting plate 110′ (e.g., wires underneath the mountingassembly 70 c; wires underneath a photovoltaic module being clamped bythe mounting assembly 70 c; wires in a space between a pair ofphotovoltaic modules being clamped by the mounting assembly 70 c).

FIG. 8F schematically illustrates the positional registration/alignmentfunction provided by the raised structure 174 of the mounting plate110′. Here the frame 62 of one photovoltaic module 58 being clamped bythe mounting assembly 70 c abuts one portion on a perimeter of theraised structure 174, while the frame 62 of another photovoltaic module58 being clamped by the mounting assembly 70 c is disposed adjacent to(or possibly abutting with) an oppositely disposed portion on theperimeter of the raised structure 174. In one embodiment, the width orouter diameter of the raised structure 174 is the same as or slightlylarger than the spacing between the two extensions 150 of the clampingmember 142. In any case, the raised structure 174 should be sized suchthat when an adjacent pair of photovoltaic modules 58 are positioned toabut oppositely disposed portions on the perimeter of the raisedstructure 174, the clamping member 142 should be positionable on thestud 114 and should properly engage these photovoltaic modules.

FIG. 9A illustrates the positional registration or alignment functionprovided by the mounting plate 110′ incorporating a raised structure 174(which thereby may be referred to as a PV module positional registrant).In FIG. 9A, the mounting devices 74 are attached to the standing seams42 such that the frame 62 of the photovoltaic module 58 engages aportion on the outer perimeter of the raised structure 174. The clampingmember 142 for each such mounting device 74 should not only be in properposition to adequately engage the frame 62 of the photovoltaic module 58shown in FIG. 9A, but the clamping member 142 for each such mountingdevice 74 should also be in proper position to adequately engage theframe 62 of another photovoltaic module 58 that would be positioned inthe uphill direction A (e.g., the arrow A indicating the direction ofincreasing elevation) from the illustrated photovoltaic module 58. Theframe 62 of this “uphill” photovoltaic module 58 would likely engage anopposing portion of the raised structure 174 (or be disposed in closelyspaced relation thereto). Any “downward drifting” of this uphillphotovoltaic module 58 should be stopped by engaging the raisedstructure 174 of the “downhill” mounting assemblies 70 c.

Now compare FIG. 9A to FIG. 9B. In FIG. 9B, the mounting assembly 70 ahas been used, and whose mounting plate 110 does not incorporate theraised structure 174 from the mounting plate 110′ of FIGS. 8A-F. Here itcan be seen that the uphill photovoltaic module 58 a (the arrow B inFIG. 9B indicating the downhill direction, or direction of decreasingelevation) has been positioned relative to the three lower mountingdevices 74 such that its frame 62 is quite close to the hole 112 of thethree lower mounting plates 110 (through which the stud 114 is directedto threadably engage the mounting device 74). The three clamping members142 associated with these three “downhill” mounting plates 110 now maynot sufficiently engage the downhill photovoltaic module 58 b.

The mounting plate 110′ from the mounting assembly 70 c of FIGS. 8A-Fuses a single raised structure 174 to provide a positional registrationor alignment function for each of the two photovoltaic modules that maybe clamped by a single mounting assembly 70 c. Other types of positionalregistration or alignment features may be incorporated by a mountingplate. One representative embodiment is illustrated in FIGS. 10A-B inthe form of a mounting plate 110″. Generally, the mounting plate 110″may be used in place of the mounting plate 110′ discussed above.Although not shown, it should be appreciated that the mounting plate110″ may also utilize the grounding projections 172 and/or wiring clips178 (and their associated apertures 184).

The mounting plate 110″ of FIGS. 10A and 10B differs from the mountingplate 110′ of FIGS. 8A-F in a number of respects. One is the shape ofthe mounting plate 110′. Each of these mounting plates 110′, 110″ may beof any appropriate shape in relation to their respective outerperimeters (e.g., circular as in the case of the mounting plate 110′;square as in the case of the mounting plate 110″; rectangular). Anotheris that the mounting plate 110″ utilizes at least two discrete PV modulepositional registrants 190. Each of the PV module positional registrants190 may be of any appropriate size, shape, and/or configuration. The PVmodule positional registrants 190 may be integrally formed with aremainder of the mounting plate 110″ as shown where they have beenstamped from the mounting plate 110″ (creating corresponding apertures192), or the PV module registrants 190 could be separately attached tothe mounting plate 110″. When the mounting plate 110″ is positioned inthe proper orientation on a mounting device 74, one of the PV modulepositional registrants 190 may be used to position one photovoltaicmodule on the mounting plate 110″ (e.g., by this first photovoltaicmodule butting up against this first PV module positional registrant190) such that it should be adequately engaged by the clamping member142, and furthermore such that the other or second photovoltaic moduleto be positioned on the mounting plate 110″ should also be adequatelyengaged by this same clamping member 142. In this regard, this secondphotovoltaic module may be positioned such that it butts up against theother or second of the PV module positional registrants 190 of themounting plate 110″.

As there are only two PV module positional registrants 190 in theillustrated embodiment of FIGS. 10A and 10B, the mounting plate 110″ mayneed to be in a certain angular position or orientation on the mountingdevice 74 such that they provide a positional registration or alignmentfunction for the two photovoltaic modules to be clamped by theassociated mounting assembly. An installer could be required to placethe mounting plate 110″ onto the mounting device 74 in the correctangular position or orientation. Another option is for the mountingplate 110″ to include one or more mounting device positional registrants194 that facilitate the positioning of the mounting plate 110″ onto theupper surface 78 of the mounting device 74 such that the PV modulepositional registrants 190 should be positioned to provide a positionalregistration or alignment function for the two photovoltaic modules tobe clamped by the associated mounting assembly. In the illustratedembodiment, the mounting plate 110″ includes a pair of mounting devicepositional registrants 194—a separate mounting device positionalregistrant 194 for each of the two opposite ends 94 of the mountingdevice 74 (e.g., one mounting device positional registrant 194 mayengage one end 94 of the mounting device 74, and another mounting devicepositional registrant 194 may engage the opposite end 94 of the mountingdevice 74). A pair of mounting device positional registrants could beutilized by the mounting plate 110″ and that engage the two oppositeside surfaces 82 of the mounting device 74 to place the mounting plate110″ in the correct angular position relative to the mounting device 74.Yet another option would be to have at least one mounting devicepositional registrant for the mounting plate 110″ that engages an end 94of the mounting device 74 and at least one mounting device positionalregistrant for the mounting plate 110″ that engages one of the sidesurfaces 82 of the mounting device 74. Any appropriate way ofpositionally registering the mounting plate 110″ relative to themounting device 74 may be utilized.

The foregoing description of the present invention has been presentedfor purposes of illustration and description. Furthermore, thedescription is not intended to limit the invention to the form disclosedherein. Consequently, variations and modifications commensurate with theabove teachings, and skill and knowledge of the relevant art, are withinthe scope of the present invention. The embodiments describedhereinabove are further intended to explain best modes known ofpracticing the invention and to enable others skilled in the art toutilize the invention in such, or other embodiments and with variousmodifications required by the particular application(s) or use(s) of thepresent invention. It is intended that the appended claims be construedto include alternative embodiments to the extent permitted by the priorart.

What is claimed is:
 1. A photovoltaic system, comprising: a buildingsurface; a plurality of mounting assemblies comprising a first mountingassembly, wherein each said mounting assembly comprises: a mountingdevice mounted to said building surface; a mounting plate positioned onsaid mounting device, wherein an upper surface of said mounting platecomprises a raised structure comprising an outer perimeter, wherein saidmounting plate extends beyond an outer perimeter of said mountingdevice, and wherein there is an open space directly below where saidmounting plate extends beyond said outer perimeter of said mountingdevice; a clamping member comprising first and second clamping legs; anda threaded clamp fastener that extends through said clamping member,through said mounting plate, and that is secured to said mountingdevice; and first and second photovoltaic modules positioned on saidupper surface of said mounting plate of said first mounting assembly inat least adjacent relation to oppositely disposed portions on said outerperimeter of said raised structure, with said first and secondphotovoltaic modules being supported by said mounting plate, and withsaid first and second photovoltaic modules being spaced from saidbuilding surface, wherein said first and second photovoltaic modules arespaced from one another and said clamping member is disposed betweensaid first and second photovoltaic modules, wherein said firstphotovoltaic module is disposed in a direction of increasing elevationof said building surface relative to said second photovoltaic module,wherein said first photovoltaic module is secured between said firstclamping leg of said first mounting assembly and said mounting plate ofsaid first mounting assembly, and wherein said second photovoltaicmodule is secured between said second clamping leg of said firstmounting assembly and said mounting plate of said first mountingassembly.
 2. The photovoltaic system of claim 1, wherein said raisedstructure of said mounting plate is centrally disposed relative to anouter perimeter of said mounting plate.
 3. The photovoltaic system ofclaim 1, wherein said threaded clamp fastener extends through a centerof said raised structure.
 4. The photovoltaic system of claim 1, whereinsaid outer perimeter of said raised structure and an outer perimeter ofsaid mounting plate are concentric relative to said threaded clampfastener.
 5. The photovoltaic system of claim 1, wherein said first andsecond photovoltaic modules abut said oppositely disposed portions onsaid outer perimeter of said raised structure of said first mountingassembly.
 6. The photovoltaic system of claim 1, wherein said raisedstructure of said first mounting assembly positionally registers each ofsaid first and second photovoltaic modules relative to said firstmounting assembly.
 7. The photovoltaic system of claim 1, wherein saidouter perimeter of said raised structure is circular in a plan view. 8.The photovoltaic system of claim 1, wherein each said mounting devicecomprises a slot and at least one seam fastener that extends throughsaid mounting device and engages a corresponding standing seam of saidbuilding surface that is disposed within said slot.
 9. The photovoltaicsystem of claim 1, wherein each of said mounting plate and said clampingmember comprises an un-threaded hole through which said threaded clampfastener extends.
 10. The photovoltaic system of claim 1, wherein saidmounting plate of each said mounting assembly is clamped onto itscorresponding said mounting device by its corresponding said clampingmember.
 11. The photovoltaic system of claim 1, wherein said mountingplate of each said mounting assembly is located between itscorresponding said mounting device and its corresponding said clampingmember.
 12. The photovoltaic system of claim 1, wherein said uppersurface of said mounting plate of each said mounting assembly has asurface area of at least about 5 in.².